Air conditioner front assembly

ABSTRACT

In preferred form an air conditioner front assembly including a unitary plastic member having a first outer frame adapted to be connected to the cabinet of an air conditioner unit. A discharge sleeve extends across the width of the frame at the top thereof and a second frame is supported in front of the first frame by a plurality of reinforcing ribs that define an inlet opening above, below and to each side of the frame for flow of return air across a filter element secured on the frame at an outlet opening on the front. The second frame includes a pair of spaced-apart parallel tracks in which slots are formed that receive spring-biased tabs on an imperforate baffle which normally covers the full planar extent of the second frame when the panel is in a closed position to damp operating noise. When in an open position, the panel is moved to one side of the second frame to uncover control means for operating the air conditioner.

United States Patent [72] Inventors FerdlnnndCJlenken Kettering; EmersonL. War-k, Vnndnla, both of, Ohio [2|] Appl. No. 886,641 [22] Filed Dec.19, I969 [45] Patented July 13, I97! [73] Assignee General MotorsCorporation Detroit, Mich.

[54] AIR CONDITIONER FRONT ASSEMBLY 3,306,l82 2/l967 Schwartz H 62/262Primary Examiner-Meyer Perlin Attorneys--W S. Pettigrew and .l C. EvansABSTRACT: In preferred form an air conditioner front assembly includinga unitary plastic member having a first outer frame adapted to beconnected to the cabinet of an air conditioner unit. A discharge sleeveextends across the width of the frame at the top thereof and a secondframe is supported in front of the first frame by a plurality ofreinforcing ribs that define an inlet opening above, below and to eachside of the frame for flow of return air across a filter element securedon the frame at an outlet opening on the front. The second frameincludes a pair of spaced-apart parallel tracks in which slots areformed that receive spring-biased tabs on an imperforate baffle whichnormally covers the full planar extent of the second frame when thepanel is in a closed position to damp operating noise. When in an openposition, the panel is moved to one side of the second frame to uncovercontrol means for operating the air conditioner.

PATENTEU JUL 1 3mm 35392.12?

sum 1 OF 2 AIR CONDITIONER FRONT ASSEMBLY This invention relates to roomair conditioners and more particularly to a unitary, multipurpose frontassembly having plural airflow passageways therein for the inlet anddischarge of air from an air conditioner cabinet to which the frontassembly is removably secured.

ln window-mounted air conditioner units it is desirable to includefilter means for removing dirt and other foreign particles from vitiatedair from a room being conditioned by the unit.

Furthermore, it is desirable from a noise standpoint to includerelatively open air passageways for discharge of conditioned air fromthe unit into the room as well as for return flow of air from the roominto the unit for conditioning.

Further noise reduction may be obtained by a front imperforate panel onwindow air-conditioning units that serves as a means for damping theoperational noises from within the cabinet.

Furthermore, it is desirable to cover control components of a unit toimprove the aesthetic appearance of the unit when in its window locatedposition within a room.

Accordingly, an object of the present invention is to provide animproved front assembly for an air conditioner that includes a unitaryframework on which is located a sliding baffle panel at a point in frontof the operative components of the air-conditioning unit to dampoperational noises within the window-mounted cabinet structure.

Another object of the present invention is to provide a lowcost frontassembly for a room air conditioner that includes unitary frameworkwhich defines a discharge sleeve across the full width of the front andwhich provides an inlet passageway on all sides of an imperforate slidepanel that is located across substantially all of the full front planarextent of the unit to damp operational noises therein and to concealcontrol components for the unit.

Yet another object of the present invention is to provide a unitaryfront assembly for an air conditioner that includes a first frameadapted to be connected to the front edge ofa window cabinet of a roomair conditioner and which includes a second frame member located infront of the first frame portion to define top. bottom and side openingsaround the second frame for unrestricted flow of return air into theunit during its operation and wherein the second frame serves as asupport for an imperforate panel for damping operational noises fromwithin the window air conditioner unit; and wherein the first framesupports a filter element in overlying relationship across the rear ofthe front to remove dust and the like from return air from the top.bottom and side ports between the two frame members.

Still another object of the present invention is to provide a low-costfront assembly easily connected to and removed from the front edge of awindow-supported room air conditioner cabinet including an unrestricteddischarge sleeve across the full width thereof at the top of the frontwhich is supported on a first peripheral frame that connects to thecabinet and wherein a second peripheral frame is supported with respectto the first frame at a point below the discharge sleeve to define asupport for an imperforate panel located across the full planar extentof the second frame member for damping operational noises within thecabinet and wherein the damping baffle is slideably supported bycoacting means on the baffle and the frame which permit the ballle to belocated in a first position to completely overlie the planar extent ofthe frame to cover controls located immediately behind the second frameand forwardly of the first frame and in a second position to permitaccess to the Controls for regulating the operation of the unit.

These and other objects of the present invention are attained in oneworking embodiment of a unitary front that includes a channel shapedperipheral flange that is adapted to be snapfit over the front edge of awindow cabinet in which are located an air-circulating fan; arefrigerant compressor; and an evaporator and condenser connected inseries flow relationship with the compressor for defining alow-temperature source across which air is circulated by the fan forconditioning the air.

The front includes an integral upper sleeve that extends across the fullwidth thereof to be supported by the first-mentioned frame. Itadditionally includes a second frame located in front of the sleeve andthe first-mentioned frame to define side, top and bottom ports for theflow of air from the room into the air-conditioning unit.

The second frame includes a pair of spaced parallel tracks into whichare snapped a plurality of spring-biased tabs on the back side of animperforate sliding panel. When in a first position, the panelcompletely covers the full planar extent of the second frame to dampoperational noise and to hide a control console located rearwardly ofthe second frame. The panel is slidable on the second frame to one sidethereof to provide access to the control panel for regulating theoperation of the unit.

Further objects and advantages of the present invention will be apparentfrom the following description, reference being had to the accompanyingdrawings wherein a preferred embodiment of the present invention isclearly shown.

In the drawings:

FIG. 1 is a view in front elevation of an air conditioner front assemblyincluding the present invention;

FIG. 2 is a front elevational view of the present invention showing asound baffle panel thereon in a position to provide access to controlcomponents;

FIG. 3 is a view from the backside of the unitary plastic front of thepresent invention showing a fragmentary portion of a removable foamfilter that is connected across the backside thereof;

FIG. 4 is an enlarged view in vertical section taken along the line 4-4of FIG. 1 partially broken away; and

FIG. 5 is a view in perspective ofa portion of the support track andconnecting tabs for slidably supporting a sound deadening panel on aframe portion ofthe front assembly.

Referring now to the drawings, a room air conditioner 10 is illustratedof the type adapted to be mounted or supported within a window frameopening.

The air conditioner 10 includes a front assembly 12 that fits over afront opening 14 in a cabinet 16 that includes a top 18 and a bottom 20that join sidewalls. one of which is illustrated at 22 in FIG. 4.Additionally. the cabinet includes a back (not shown).

For purposes of the present invention, it is only necessary tounderstand that the cabinet l6 serves to enclose the operativecomponents of the air conditioner unit including an evaporator which istypically located at the front of the cabinet 16 across most of theplanar extend thereof; an air-circulating fan for drawing air across theevaporator for cooling it and then for returning the circulated air backinto a room being cooled by the unit.

The unit further includes an electric motor driven refrigerantcompressor which connects in series flow relationship with a condenserand an expansion device to the evaporator which in turn is connected tothe inlet of the compressor.

One characteristic of units of this type is that they have an observableoperational noise level in part due to the vibration modes present inboth the air-circulating components of the system and in therefrigerant-circulating components thereof.

The front assembly 12, in accordance with certain principles of thepresent invention, includes an improved baffle arrangement that servesto damp noise emanating from the cabinet 16 and additionally serves tocoverup control components that regulate the operation of the unit.

More particularly, in the illustrated arrangement, the baffle isillustrated as a horizontally slidable bafi'le 24 which is slidablysupported on the front of a unitary, multipurpose cabinet front 26. Thefront 26 includes a peripheral cabinet connection channel 28 that has apair of spaced sidewalls 30,

32 joined at their upper ends by a top frame member 34 and at the lowerend thereof by a bottom frame member 36.

The baffle 24 is made of high-impact polystyrene material and in oneworking embodiment has a thickness of 0.120 inches which adequatelyreduced noise from a unit having the following specifications:

Cabinet 16:

Width 24% inches. Height 14 inches. Depth 25,; inches. Air circulation(maximum oool). 310 0.12m. Fan motor speed (maximum c0011.. 1,075r.p.rn. Fan motor I P V 111. Compressor motor speed 3 450 r.p.m. Fantype v v Centrifugal.

The sidewalls 30, 32 of the connection channel 28 are joined by acrosspiecc 38 which is inclined outwardly and upwardly of the bottomframe member 36 as best illustrated in FIG. 4.

Additionally, the unitary cabinet front 26 includes a discharge sleeve40 having an upper wall 42 that is directed rearwardly and at a slightdownward inclination with respect to the top frame member 34. A lowerwall 44 thereon is connected at its front edge to the front edge of thecrosspiece 38 and is directed rearwardly thereof at an upwardinclination to define a discharge passage 46 which extends through thefull width of the cabinet front 26 and which has an outwardly divergingsection to receive air discharged by the fan within the cabinet 16 fordistribution into the room being cooled by the unit 10. Braces 47 jointhe walls 42, 44 at the entrance to passage 46.

in the illustrated arrangement within the passageway 46 is located agrill assembly 48 which includes a movable frame 50 having a top 52, abottom 54 and sidewalls, one of which is shown at 56. The sidewalls 56fit over pins 57 on walls 30, 32 for pivotally securing frame 50 on thefront 26.

Between the sidewalls of the frame 50 are located a plurality ofvertically spaced fixed horizontal vanes 58 which are connected to theframe 50 at the opposite ends thereof to he moved therewith on pins 57to vary their inclination with respect to the front end of thepassageway 46. The vanes 58 are connected by front located, spacedvertical struts 60 on the assembly 48 best seen in FIGS. 1 and 2.

Additionally, the grill assembly 48 includes a plurality of horizontallyspaced movable vertical vanes 62 each of which has the opposite endsthereof pivotally connected to the frame 50 and each of which includes atab 64 thereon, one of which is shown in FIG. 4, that connects to one orthe other of two horizontally reciprocated actuating bars 66, 68.

Each of the bars 66, 68 has a handle 69 extending in front of thecabinet as best shown in FIG. 1 for pivotally positioning the vanes 62in passageway 46 to divert airflow through the passageway 46 to oppositesides of the front ofthe unit 10.

The aforedescribed grill assembly is merely representative of onesuitable arrangement for giving a varied flow pattern outwardly of thepassageway or flow channel 46 of the conditioned air into the room.

The front assembly 12 also includes a forwardly located frame 70 whichserves to slidably support the horizontal baffle 24 with respect to aninlet opening 72 in the front assembly 12 through which operating noiseis normally directed. More particularly, the baffle panel 24 issupported by the support of the front frame 70 to overlie substantiallythe full planar extent of that inlet opening 72 to produce a highlyeffective noise shield between the operative components within thecabinet 16 and the room interior.

The support frame 70 is integrally connected to the center crosspiece 38by a plurality of inclined reinforcing ribs 74 which are located atspaced-apart points across the full width of the front assembly 12 as isbest seen in FIG. 2.

The reinforcing ribs 74 cooperate to define a plurality of inletopenings 76 into the front assembly 12 at a point in mediately below theupwardly and forwardly inclined crosspiece 38.

Additionally, the frame 70 is integrally connected at the bottom thereofby a plurality of like spaced-apart reinforcing ribs 74 which arelocated at spaced-apart points across the bottom width of the frontassembly 12 to define a plurality of bottom inlet openings 78thereacross also which communicate with the interior of the frontassembly 12 and lead to the inlet 72 to the cabinet 16.

A plurality of side ribs 80 form spaced-apart vertically tiered sideopenings 82 to one side of a framed control access member 84 in frame70.

The member 84 is connected by ribs 86 to the sidewall 32 of frame orconnection channel 28 at one end thereof and to a side post 88 on themember 84 to define a still further plurality of side openings 90 in thefront assembly 12 which lead to the inlet opening 72.

On the opposite side of the frame 70 is located a second upstanding post92 which connects to one end of a plurality of vertically tieredreinforcing ribs 94 having the opposite end thereof connected to thesidewall 30 of the connection frame or channel to define yet anotherplurality of side openings 96 leading to the inlet openings 72.

The aforedescribed plurality of openings in the frame 70 define arelatively unrestricted opening in the front assembly through whichreturn air from the room can flow without producing a high velocity ofair that results in undesirable whistling noises or the like.

Furthermore, the inlet flow through the openings 76, 78, 82, 96 arebehind the baffle 24 which serves to damp any minor amount of airflownoise that might exist as the air is being drawn through the frontassembly 12 around the top, bottom and sides of the panel 24.

Another important feature of the present invention is the manner inwhich the panel 24 is supported on the frame 70.

More particularly, in the illustrated arrangement the frame 70 includesa top guide bar 100 extending across the top front thereof connectingthe forward ends of the reinforcing ribs 74 and a plurality of anglemembers 102 that are located at spaced-apart points along the length ofthe guide rod 100. The angle members include a depending leg portionwhich is integrally formed with the upper flange of an elongated track104 which extends between the vertical strut 81 of the frame 70 to thevertical strut 92 thereof as is best seen in FIG. 3.

The track 104 includes three spaced slots 106 therein.

Additionally, the frame includes a second elongated track 108 that isconnected between the same sides of the frame 70 in which are formedthree slots 110 located in spaced parallelism to the slots 106 in thetrack 104.

The tracks are reinforced with respect to one another by a plurality ofvertical struts 112 that have the opposite ends thereof connected to thetracks 104, 108 respectively to reinforce the frame 70.

The frame further includes a bottom located guide bar 114 which isrigidly connected to the underside of the track 108 by a plurality ofspaced-apart upstanding angle members 116.

in accordance with certain principles of the present invention, thebaffle 24 includes an undercut recess 118 along the rear bottom edgethereof which is slidably received by the bar 114 in supportedrelationship thereon.

The upper end of the baffle is maintained in a sliding supportedrelationship on the front face of the upper guide rod 100.

To prevent rattling of the baffle 24 with respect to the frame, itincludes a plurality of spaced-apart spring tabs 120 thereon each ofwhich includes a first arm 122 with a barb 124 thereon which is springbiased away from a like arm 126 having a like barb 128 thereon as isbest seen in FIG. 5. in the illustrated arrangement each of the pairs oftabs 120 is adapted to be press fit within one of the slots 106, 110where they spring apart to locate the backside of the barbs 124, 128 inin terlocked relationship with the track members 104, 108 so as tosecure the baffle 24 in a spring-biased sliding engagement with thefront of each of the guide rods 100, 114.

In order to release the baffle 24, the front assembly 12 is removed fromthe cabinet l6 by pressing downwardly to release a plurality of rollers130 that are supported on the ends of spring arms 132 held in placewithin the top and sides of the channel-shaped connecting flange 28 tobias the rollers 130 into an interlocking engagement with a recess l34formed in a front edge or side edge of the cabinet 16.

The tangs I24, 128 then are accessible and can be pressed together toallow the pairs of tabs 120 to be removed from the slots 106, 110 toreplace the baffle 124 or locate it for sliding movement with respect tothe front of the assembly 12.

In addition to overlying the full planar extent of the inlet opening 72,the baffle 24 can be moved between two operative positions, In the firstoperative position as shown in FIG. I, the baffle 24 covers the fullwidth of the front assembly l2 and in addition to serving as a means forbaffling noise of operation within the cabinet 16 serves to cover theframe member 84 that defines access to a plurality of control knobs 136,I38, I40 which are connected to control means for the cooling system toregulate the operation of the unit, In the closed position of FIG. 1,the bafi'le has the pairs of tabs 120 thereon located to the far leftside of the slots 106, [10 as viewed from the front of front assemblyl2.

In FIG. 2, the baffle 24 is shown in an open position wherein it stillcovers the full planar extent of the inlet opening 72 to the device andis located to one side of the cabinet wherein the control knobs 136,I38, 140 are accessible.

In both of these positions, the pairs of tabs 120 serve to maintain thebackside of the baffle 24 at the top and bottom thereof tightly againstthe guide rods 100, 114 to prevent any undesirable relative movementtherebetween that would produce vibration levels that would defeat theinitial purpose of the panel 24, namely, to damp noise of operation.

In the illustrated arrangement, the inlet opening 72 also has a filterlocated thereacross which is removable as part of the front assembly 12.

More particularly, the filter includes a rectangularly shaped flexiblefoam filter element 142 which has the edges thereof at selective pointsalong the perimeter of the filter element [42 fastened over connectionclips 143 that have a barbed end I44 thereon that holds the filterperiphery 142 in place with respect to support posts 146 that arelocated at spaced-apart points along the frame 28 as best shown in FIG.3.

By virtue of the aforesaid arrangement, replacement of the bafi'le 24and the filter 142 are easily made by merely removing the front assembly12 from the cabinet l6 for access to the filter unit [42 and the tabs Ion the baffle 24 From the above description it will be appreciated thatthe front assembly serves multiple purposes including defining a highlyeffective low noise, inlet passageway for return airflow that isfiltered before passing through the operative components of awindow-mounted room air conditioner; and also defining a relatively openfull-width discharge passageway in which can be located a grill havingvane means for regulating the direction of outlet air into the roombeing conditioned by the unit.

Still further, the means for forming the inlet includes a frame on whicha movable sound-dampening baffle 24 is mounted for sliding movementbetween a first closed position to damp noise from within the cabinetand a second open position wherein the same noise damping properties areobtained while permitting access to control components of the unit.

While the embodiments of the present invention, as herein disclosed,constitute a preferred form, it is to be understood that other formsmight be adopted.

What we claim is:

1. An air conditioner front assembly including a peripheral frameadapted to be connected to the front edge of an air conditioner cabinet,a second frame located in front of said peripheral frame, means defininga pair of spaced-apart parallel tracks on said second frame, a pair ofspaced-apart slots formed in said track, a sound-damping baffle locatedin front of said second frame, a plurality of spring-biased tabs on theback of said baffle having the ends thereof extending into the slots ofsaid tracks, barbs on said tabs interlockingly connected to the backsideof said tracks holding said baffle against the front of said secondframe, said slots extending a predetermined horizontal distance throughsaid tracks, said spring-biased tabs being horizontally movable withinsaid slots into a first position wherein said baffle is located to coverthe full planar extent of said front frame, said tabs being located insaid slots in a second position to locate said baffle to one side ofsaid frame, an access opening in said front assembly to control means onthe air conditioner, said baffle covering said opening when in its firstposition, said access opening being uncovered for operation of thecontrols when said panel is in its second position.

2. An air conditioner front assembly comprising: a peripheral frameadapted to be connected to the front edge of an air conditioner cabinetincluding a pair of spaced-apart sides, a top and a bottom, a dischargesleeve extending across the width of said front assembly having a topand bottom connected to the sides of said peripheral frame, a crosspieceextending between said sides of said peripheral frame formed integralwith said sleeve bottom throughout the full horizontal extent thereof, aplurality of upper outwardly, extending reinforcing ribs connected tosaid crosspiece at one end thereof, an upper guide bar connected to theopposite ends of said upper ribs extending between said side portions ofsaid peripheral frame, a lower guide bar extending below said upperguide bar between sides of said peripheral frame, a pair of spaced-aparttracks located rearwardly of said upper and lower guide bars andinwardly of said reinforcing ribs, a baffle having a plurality ofconnecting means on the back thereof, coacting means on said connectingmeans and said tracks for supportingly receiving said baffie for slidingmovement across the front of said upper and lower guide bars, saidcoacting means including means for maintaining said bafile inspringbiased supported sliding relationship with said guide rodsthroughout the sliding movement thereof with respect to said front,control means behind said front, said baffle having a first position tocover said control means and having a second position wherein saidcontrol means are exposed,

3. An air conditioner front assembly comprising: a peripheral frameadapted to be connected to the front edge of an air conditioner cabinetincluding a pair of spaced-apart sides, a top and a bottom, a dischargesleeve extending across the width of said front assembly having a topand bottom connected to the sides of said peripheral frame, a crosspieceextending between said sides of said peripheral frame formed integralwith said sleeve bottom throughout the full horizontal extent thereof, aplurality of upper outwardly extending reinforcing ribs connected tosaid crosspiece at one end thereof, an upper guide bar connected to theopposite ends of said upper ribs extending between said side portions ofsaid peripheral frame, a lower guide bar extending below said upperguide bar between sides of said peripheral frame, a pair of spaced-aparttracks located rearwardly of said upper and lower guide bars andinwardly of said reinforcing ribs, a baffle having a plurality ofconnecting means on the back thereof, coacting means on said connectingmeans and said tracks for supportingly receiving said baffle for slidingmovement across the front of said upper and lower guide bars, saidcoacting means including means for maintaining said baffle in supportedsliding relationship with said guide rods throughout the slidingmovement thereof with respect to said front, control means behind saidfront, said baffle having a first position to cover said control meansand having a second position wherein said control means are exposed,said frame further including a plurality of spaced rearwardly extendingposts having one end thereof connected to said crosspiece, a secondplurality of posts connected to said peripheral flange across the basethereof, a flexible foam filter extending throughout the planar extentof said frame to remove particulate matter from return air to the a rndit oner.

1. An air conditioner front assembly including a peripheral frameadapted to be connected to the front edge of an air conditioner cabinet,a second frame located in front of said peripheral frame, means defininga pair of spaced-apart parallel tracks on said second frame, a pair ofspaced-apart slots formed in said track, a sound-damping baffle locatedin front of said second frame, a plurality of spring-biased tabs on theback of said baffle having the ends thereof extending into the slots ofsaid tracks, barbs on said tabs interlockingly connected to the backsideof said tracks holding said baffle against the front of said secondframe, said slots extending a predetermined horizontal distance throughsaid tracks, said spring-biased tabs being horizontally movable withinsaid slots into a first position wherein said baffle is located to coverthe full planar extent of said front frame, said tabs being located insaid slots in a second position to locate said baffle to one side ofsaid frame, an access opening in said front assembly to control means onthe air conditioner, said baffle covering said opening when in its firstposition, said access opening being uncovered for operation of thecontrols when said panel is in its second position.
 2. An airconditioner front assembly comprising: a peripheral frame adapted to beconnected to the front edge of an air conditioner cabinet including apair of spaced-apart sides, a top and a bottom, a discharge sleeveextending across the width of said front assembly having a top andbottom connected to the sides of said peripheral frame, a crosspieceextending between said sides of said peripheral frame formed integralwith said sleeve bottom throughout the full horizontal extent thereof, aplurality of upper outwardly, extending reinforcing ribs connected tosaid crosspiece at one end thereof, an upper guide bar connected to theopposite ends of said upper ribs extending between said side portions ofsaid peripheral frame, a lower guide bar extending below said upperguide bar between sides of said peripheral frame, a pair of spaced-aparttracks located rearwardly of said upper and lower guide bars andinwardly of said reinforcing ribs, a baffle having a plurality ofconnecting means on the back thereof, coacting means on said connectingmeans and said tracks for supportingly receiving said baffle for slidingmovement across the front of said upper and lower guide bars, saidcoacting means including means for maintaining said baffle inspring-biased supported sliding relationship with said guide rodsthroughout the sliding movement thereof with respect to said front,control means behind said front, said baffle having a first position tocover said control means and having a second position wherein saidcontrol means are exposed.
 3. An air conditioner front assemblycomprising: a peripheral frame adapted to be connected to the front edgeof an air conditioner cabinet including a pair of spaced-apart sides, atop and a bottom, a discharge sleeve extending across The width of saidfront assembly having a top and bottom connected to the sides of saidperipheral frame, a crosspiece extending between said sides of saidperipheral frame formed integral with said sleeve bottom throughout thefull horizontal extent thereof, a plurality of upper outwardly extendingreinforcing ribs connected to said crosspiece at one end thereof, anupper guide bar connected to the opposite ends of said upper ribsextending between said side portions of said peripheral frame, a lowerguide bar extending below said upper guide bar between sides of saidperipheral frame, a pair of spaced-apart tracks located rearwardly ofsaid upper and lower guide bars and inwardly of said reinforcing ribs, abaffle having a plurality of connecting means on the back thereof,coacting means on said connecting means and said tracks for supportinglyreceiving said baffle for sliding movement across the front of saidupper and lower guide bars, said coacting means including means formaintaining said baffle in supported sliding relationship with saidguide rods throughout the sliding movement thereof with respect to saidfront, control means behind said front, said baffle having a firstposition to cover said control means and having a second positionwherein said control means are exposed, said frame further including aplurality of spaced rearwardly extending posts having one end thereofconnected to said crosspiece, a second plurality of posts connected tosaid peripheral flange across the base thereof, a flexible foam filterextending throughout the planar extent of said frame to removeparticulate matter from return air to the air conditioner.